Monolithic hollow wall



March 11, 1952 T, M O'NEAL 2,589,021

MONOLITHIC HOLLOW WALL Filed May 26, 1947 Patented Mar. 11, 1952 UNITEDSTATES PATENT OFFICEy 2 Claims.

This invention relates to a monolithic Wall and means for constructingthe same and it is an object of the invention to provide a wall of thiskind which is hollow and reinforced and constructed in a manner toprovide space for air circulation.

It is also an object of the invention to provide a wall of this kindwhich excludes the necessity of painting, yet allows the use of coloringmatter to be mixed with the cementitious material desired and whereinthe construction and method of producing the wall is such to assure thewall becoming harder as time goes on which is reverse to the generaltype of construction of wood and cement.

It is a still further object of the invention to provide a device ofthis kind which does not require the use of wood, thereby assuring theWall being entirely reproof.

These and other objects and advantages of the invention will be foundfrom a reading of the subjoined description with the aid of the attacheddrawing.

In the drawing:

Figure 1 is a horizontal sectional view showing the first steps inerecting a wall;

Figure 2 is a similar view showing additional steps;

Figure 3 is a similar view showing a finished wall; and

Figure 4 is a fragmentary vertical section of a foundation constructedin accordance with the present invention.

As illustrated in the accompanying drawing, W denotes a false wall orbacking of suitable material and against which the inner side of thewall is to be erected and formed.

In the producing of the wall the first step consists in attaching byscrews I or in any other suitable manner, a sheet 2 of a reticulated orforaminous material preferably one that is made up of a coarse meshmetal fabric having a heavy paper pulp or gunnysack covering or backing2', but a suitable metal fabric without such backing may be employed.This sheet 2 is placed fiat against the backing or wall W and it ispreferred that the attachments l be such that when desired, the backingor wall W can be easily removed after completion, or partial completion,as thecase may be,`of the monolithic wall.

After the sheet 2 has been applied, a layer 3 of suitable cementitiousmaterial, such as wellknown Gunite ^cerrlent is applied for a thicknessof approximately 3A of an inch, although this thicknessvis not to beunderstood as being an essential part of the invention as such thicknessmay be varied as. the requirements of practice may prefer.

Before the layer 3 has set, the stud reinforcements 4 are applied orplaced. Each of these stud reinforcements 4 is formed of lengths of theaforesaid fabricated material and is bent or folded to have a V-shapedsection with the apex outwardly disposed. The free longitudinal marginalportions of the sides of the reinforcements are freed of the heavy paperreinforcement 2', where this type of fabric is used, for about an inchfrom the edge, and this is bent to an angle as at 4 and forced into thecement layer 3 and against the fabric sheet 2. The stud reinforcements 4may be of such number desired and spaced apart as the requirements ofpractice may deem best.

By removing the paper reenforcement of the width of approximately aninch from the edge of the fabric and then bending the metal of thefabric at the newly formed edge, a portion of the paper reenforcementwill be extended into the cement lamination as shown. However a greaterextent or width of the paper reenforcement may be removed and when theedge of the fabric has been forced into the cement layer or laminationit will be seen that the cement material will bond through the meshes ofthe fabric above the angle 4' thereby more rmly locking the fabricmaterial in position.

After each of the reinforcements 4 has been bonded in place,cementitious material is applied thereto, preferably Gunite, and iioatedto a desired thickness to provide the encasing layers 6. These layers 6are floated to desired finish and allowed to set from between four toten hours. These layers 6 and the fabricl provide the hollow studs S.

The outer or meeting end portions of the layers 6 of each stud S aresubstantially coplanar with the adjacent apex of the associatedreinforcement Il. In the formation of the layers l, the outer or meetingend portions, at the apex of the associated reinforcement 5, haveembedded therein the wire strands l, which are secured to thereinforcement and extend outwardly therebeyond a desired distance for apurpose to be hereinafter more particularly referred to.

After the layers 6 have been allowed to properly set, a foraminous orreticulated sheet 8 of the reinforcing fabric is laid directly acrossthe apices of the reinforcements Where such paper covered fabric is usedthe paper covering 2 is cut away to provide for the extensiontherethrough of the wires l. These portions of said wires l are securedto the fabric strands whereby the sheet 8 is rmly held in place. A layerI0 of cementitious material is then applied to the surface of the fabric8, said layer I being Gunite cement. This layer I0, of course, is ofdesired thickness and is allowed to set. After the layer I0 has set asdesired the wall or backing W is removed.

The paper backing of the fabric is removed to the width of the apex ofthe stud S so that the cement of layer l0 may pass through fabric 8 andbond firmly to the material forming the stud layer 6.

After the wall or backing W has been removed, the exposed face of thesheet 2 is washed oil, after which there is applied thereto la layer Hof cementitious material and of a thickness desired.

In view of the foregoing it is believed to be readily apparent that bythe method and manner set forth, a monolithic wall is provided which isof a, hollow type having vertically disposed nues to provide space forair circulation and it is also readily understood from the foregoingthat the construction and method is one whereby the completed Wall ispractically substantially indestructible by fire, water, termites andthe like, and that when completed', the necessity of using wood orkindred material is entirely eliminated.

While the invention as herein disclosed is particularly adapted for theconstruction of a vertical wall, it is believed to be obvious that itcan be employed to the same advantage in the production of ceilings androofs. It is to be stated -that in the construction of roofs, heavyreinforcing material should be used.

It is also to be stated that the outer surfaces of the completed wallmay be smooth or otherwise nshed as may be provided and that thecharacter of thev wall' is such as to eliminate the necessity ofpainting, although desired coloring may be effected by mixing thesuitable color material with the cementitious material.

It is also to be stated that with the use of Gunite cement, the wallbecomes more and more solid as timey passes which is reverse to thegeneral type of constructions of wood and cement of today.

Figure 4 illustrates the construction of a foundation in accordance withan embodiment of the present invention. In such construction, the spacerelements or studs 2 are each formed of a length of the metal lath ormetal fabric, backed with heavy' paper or gunnysack, as before stated,is shaped or bent into the form of a trough substantially V-shaped incross-section, of the desired height and width. An approximate dimensionwould be six inches by twelve inches, the twelve inches representing thedepth. This trough like form is made with the tapering side walls i6 andthe connecting flat top'wall Il. The side walls I6 have a portion alongeach longitudinal edge of about four inches in width, turned outwardlyto form a flange I6. When using a fabric having theA applied heavy paperbacking, the metal of the fabric is placed on the outer side of thetrough structure.

A trench or excavation l2 is formed to desired depth and to a true leveland the preformed metal fabric trough is then placed in the trench ininverted position as shown in Figure 4, with the outturned flanges IB'resting upon the bottom surface of the trench.

After being placed in the position shown the Gunite cement is applied,covering the sides and top and the outturned flanges I6 as illustrated,the cement material being designated I9. After the application of thiscement material there is then immediately embedded in the cementmaterial at each side of the portion I'I of the metal fabric form, astrip of the metal fabric from which the paper backing has been removed.Such a strip may be preferably about four inches in width, the depth ofthe cement into it is embedded being approximately two inches thusleaving about two inches of the metal fabric projecting upwardly. Theseprojecting strips i8 of the metal fabric provide a footing for the wallwhich is to be mounted or built up on the foundation thus constructed.

After forming such a foundation the hereinbefore described wallstructure may be built up thereon by placing the false wall W verticallyagainst the outer side of the foundation and then building up themonolithic wall thereon in the manner hereinbefore described.

The term Wall as noted in the foregoing description and as also embodiedin the appended claims, is intended to cover not only the usual uprightwalls of a building structure but also ceilings, roofs, rafters andfoundation constructions.

From the foregoing description it is thought to be obvious that a wallconstructed in accordance with my invention is particularly well adaptedfor use by reason of the convenience and facility with which it may beassembled and operated.

With the present invention a much cheaper wall can be constructed thanis possible by using the present methods of setting up concretestructures. Accordingly the invention is particularly well adapted tothe setting up of inexpensive houses such as farmers tenant houses,summer cottages, barns and the like. By eliminating completely thecement lamination I0 and the fabric reinforcement 8 there may beproduced a single thickness wall finished smooth on the inside, with thestuds S protruding on the outside of the building.

It is to be particularly pointed out thatthe construction hereindisclosed is in no way similar to the well-known poured concrete type ofconstruction where the use of heavy expensive forms is required. Asidefrom the single initially set up false wall, no form is required incarrying out the present invention.

I claim:

l. A monolithic wall construction, comprising spaced sheets of areticulated reinforcing material, a layer of a cementitious material oneach side of one of said sheets, substantially V-shaped members formedof folded lengths of said reinforcing material equidistantly spacedalong one of the sides of said one sheet with the edges of the sideportions thereof embedded within the cementitious layer on that sideforming spaced hollow studs, a backing sheet covering the inner surfaceof each of said V-shaped members, a layer of cementitious material oneach of the outer surfaces of said members, the second sheet of saidreinforcing material extending between and joining the apices of saidmembers and secured thereto, and a layer of cementitious material on theouter surface of said second reinforcing sheet.

2. The wall construction as defined in claim 1, with the said edges ofthe side portions of said members'V out-turned and forming footings'disibosed in contact with the adjacent surface of the 'Number rst namedreinforcing sheet. 1,538,681 THEODORE MATTHEW ONEAL. 2,007,689 2,042,438REFERENCES CITED 5 2,065,355 The following references are of record inthe 133,633 me of this patent: 2,230,430

UNITED STATES PATENTS Number Name Date 10 Number 1,307,793 Schulz June24, 1919 249,999 1,484,484 Flagg Feb. 19, 1924 Name Bate Buckhout May19, 1925 Merrill July 9, 1935 Wells May 26, 1936 Twachtman Dec. 22, 1936Weesner Nov. 29, 1938 McKee Feb. 4, 1941 FOREIGN PATENTS Country DateItaly 1926

